Non-Metallic Raceway for Wiring and Fiber Optic Cable and Method of Forming Raceway

ABSTRACT

A continuous, non-metallic conduit for conductors, such as electrical wiring and/or fiber optic cable. The continuous conduit being formed from at least one pair of first and second conduits having enlarged ends coupled together. The enlarged ends are belled or otherwise have a diameter greater than that of the straight run (non-belled) portions of the conduit. The enlarged ends of the conduit being coupled together by fusion or welding, and an internal bead or ridge being formed by the coupling process. The enlarged ends are dimensioned such that the internal bead or ridge formed at the junction between the two enlarged ends does not project radially inward to a position equal to or less than the diameter of the straight run portion of the conduits. The continuous conduit is configured to allow the conductor to be passed therethrough such that the conductor does not contact the internal bead or ridge.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 60/960,283 filed Sep. 24, 2007, the entire content of which ishereby incorporated by reference into the present application.

FIELD OF THE INVENTION

The present invention relates to a non-metallic conduit or raceway forconductors, such as electrical wiring and/or fiber optic cable. Inparticular, the present invention relates to non-metallic conduitshaving enlarged ends coupled together to form a continuous conduit,wherein the continuous conduit is configured to allow a conductor to bepassed therethrough without contacting internal ridges formed atjunctions of the coupled-together enlarged ends.

DESCRIPTION OF RELATED ART

Systems for forming or joining conduit or piping sections comprised ofpolyethylene or polyvinylchloride (PVC) piping have long been in use.U.S. Pat. No. 6,982,051 (hereinafter “the '051 patent”) and publishedapplication U.S. Patent Pub. No. 2006/0071365 (application Ser. No.11/244,123) (hereinafter “the '365 publication”) disclose a method andapparatus for use in a fusion process for PVC conduit to provide anessentially single piece of PVC conduit. The entire content of each ofthe foregoing documents is hereby incorporated by reference.

Fused conduit of the type disclosed in the '051 patent and the '365publication have general applications in methods of water or gas lines.In such applications, little concern is given to an internal bead orridge formed within joined conduits. As shown and described in the '051patent and the '365 publication, external and internal beads are formedalong the external and internal surfaces of the conduit at the joint ofthe joined conduit pieces. Each bead may have irregular surfaces andsharp edges. For the internal bead, such irregularity may result in asignificant reduction to the inside diameter and may make the conduitunsuitable for carrying electrical wiring or fiber optic cable.

The resultant external bead extending around the fused joint areas canbe substantially removed and smoothed for appearance sake. However, theinternal bead remains in place because it typically does notsignificantly adversely affect the flow of liquids or gasses. While the'051 patent suggest that the internal bead may also be removed ifleaving it would be adverse to the flow of liquids or gasses, the factof the matter is that such removal is expensive and generally requiresmultiple reaming tools. Further, such removal is typically done “blind”within the conduit and success generally cannot be assured. Moreover,such removal (e.g., grinding) of the internal bead may weaken the joint,thereby rendering the conduit unsuitable for use.

In raceways for electrical wiring or fiber optic cable, it is importantthat the internal surfaces of the raceways do not have internalprojections from the fusion process that would obstruct the wiring orcable as it is pulled or pushed through. It is also possible for thewiring or cable to be cut or pierced by the internal projections. Inevaluating PVC conduit formed by the process disclosed in the '051patent and the '365 publication, cut-away sections of the PVC conduitshowed internal beading or ridging making it unsuitable for use asraceways for electrical wiring or fiber optic cable.

BRIEF SUMMARY

Exemplary embodiments of the present invention include (i.e., comprise)a non-metallic raceway configured to facilitate passage of a conductor,a method of forming a continuous conduit from a first hollow conduit anda second hollow conduit, and a continuous conduit for housing anelectrical or optical conductor.

In one aspect of the present invention, a non-metallic raceway isconfigured to facilitate passage of a conductor and comprises a pair ofnon-metallic hollow conduits, including a first non-metallic conduit anda second non-metallic conduit. The first and second non-metallic hollowconduits each have a first belled end with a first inner diameter, asecond belled end with the first inner diameter, and a cylindricalportion between the belled ends and with a second inner diameter. Thepair of non-metallic hollow conduits is fused together at first belledends to form a fused portion, and the fused portion includes an internalridge and an external ridge. The internal ridge has a third innerdiameter, and the first, second, and third inner diameters are sizedsuch that a conductor passed through the raceway does not contact theinternal ridge. The first inner diameter is greater than the secondinner diameter, and the third inner diameter is greater than the secondinner diameter and less than the first inner diameter.

In another aspect of the present invention, a method of forming acontinuous conduit from a first hollow conduit and a second hollowconduit comprises positioning a bell-shaped end of the first hollowconduit adjacent a bell-shaped end of the second hollow conduit suchthat respective circumferences of the hollow conduits are substantiallyaxially aligned and substantially permanently fusing the positioned andaligned bell-shaped ends together to form a fuse joint between thebell-shaped ends. The substantially permanently fusing forms an internalprotrusion at the fuse joint, the internal protrusion protrudessubstantially radially inward and has the third inner diameter, and theinternal protrusion does not extend inward to an inner diameter ofnon-belled portions of the first hollow conduit and the second hollowconduit. The substantially permanently fused first and second hollowconduits forming the continuous conduit are configured so as to preventa conductor passed through the continuous conduit from contacting theinternal protrusion.

Another aspect of the invention includes a continuous conduit forhousing an electrical or optical conductor. The conduit comprises afirst elongated conduit having a cylindrical portion and enlarged endswith a diameter larger than the cylindrical portion and a secondelongated conduit having a cylindrical portion and enlarged ends with adiameter larger than the cylindrical portion. One of the enlarged endsof the first elongated conduit is coupled to one of the enlarged ends ofthe second elongated conduit, and the coupled enlarged ends forming ajoint which includes a protrusion that projects radially inward. Thecoupled first and second elongated conduits having the joint with theinwardly projecting projection are configured to house the electrical oroptical conductor so the conductor does not contact the internal ridge.

The foregoing and other aspects of the present invention, as well as itsvarious features and advantages, will be more readily appreciated fromthe following detailed description taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate embodiments of the invention. Theinvention will be best understood by reading the ensuing specificationin conjunction with the drawing figures, in which like elements aredesignated by like reference numerals, and wherein:

FIG. 1 is an external view of a portion of a continuous conduitaccording to an embodiment of the present invention;

FIG. 2 is a cross sectional view of the continuous conduit portion shownin FIG. 1;

FIG. 3 is a cross sectional view the continuous conduit in FIG. 1 takenalong line BB;

FIG. 4 shows a plurality of dual bell joints forming a continuousconduit according to an embodiment of the present invention, with thetop illustration representing an external view and the bottomillustration representing a cross sectional view; and

FIG. 5 is a flow chart representation of a method for forming acontinuous conduit according to an embodiment of the present invention.

DETAILED DESCRIPTION

The embodiments described below represent non-limiting examples of thepresent invention.

Generally speaking, the present invention provides (1) a continuousconduit that is configured to facilitate traversal (e.g., pushing orpulling) of a conductor, such as an electrical wiring, an electricalcable, a fiber optic wire, a fiber optic cable, a wire TYP, othercommunication or data transmission means, or combination thereof throughan interior volume thereof without obstructing or damaging theconductor; (2) a continuous conduit that is configured to house aconductor in the interior volume thereof; and (3) a continuous conduitthat is configured to be traversed through a cavity.

FIG. 1 shows a portion of a continuous conduit or raceway 1 according toan embodiment of the present invention. The portion of the continuousconduit 1 shown in FIG. 1 includes a first conduit 2 and a secondconduit 3 coupled together at a junction forming a joint 6.

The first conduit 2 and the second conduit 3 can be of any suitableconfiguration and of any suitable dimensions. For example, in FIG. 1,the first conduit 2 has a “straight run” or elongated portion and anenlarged end 4. Similarly, the second conduit 3 has a straight run orelongated portion and an enlarged end 5. Though not explicitly shown inFIG. 1, both ends of the first conduit 2 can have enlarged ends and bothends of the second conduit 3 can have enlarged ends. Additionally,non-coupled ends (i.e., conduits at ends of the continuous conduit 1)may have ends that are not enlarged.

Enlarged ends 4, 5 can be of any suitable configuration and of anysuitable dimensions. Generally, the ends are “enlarged” in the sensethat they have an inner diameter at ends thereof greater than an innerdiameter of the straight run or elongated portion to which they arecoupled. Moreover, the enlarged ends 4, 5 preferably do not have anyportion thereof having an inner diameter equal to or less than the innerdiameter of the straight run portion to which they are coupled. FIG. 1,for example, shows the enlarged ends 4, 5 being substantiallybell-shaped or flared. The enlarged ends 4, 5 are coupled together toform the continuous conduit 1. The junction at which the enlarged endsare coupled together forms joint 6.

Enlarged end 4 and enlarged end 5 can be coupled together by anysuitable means, such as fusing, welding, butt welding, gluing, etc. andcan be performed by any suitable means, including, but not limited to,by automated machines, non-automated machines, manually, or combinationthereof. In an embodiment of the present invention, the enlarged ends 4,5 are fused together using the method substantially as described in the'051 patent and the '365 publication. Coupling the enlarged ends 4, 5together can result in an outer protrusion 7 and an inner protrusion(not shown in FIG. 1) being formed at joint 6.

The outer protrusion 7 projects generally outwardly from the joint 6 byany suitable amount and can take any suitable form or shape. The outerprotrusion 7 can be formed after coupling of the enlarged ends 4, 5. Forexample, the outer protrusion 7 can be formed to take a specific shape,to be reduced, or to be substantially removed.

FIG. 2, is a cross sectional view of the continuous conduit 1 portionshown in FIG. 1. FIG. 2 shows the inner protrusion 8 formed on theinside of the conduits at joint 6. Inner protrusion 8 projects generallyinwardly from the joint 6, along the entirety of the joint 6 (i.e.,along the circumference) and can project inward by any suitable amountor take any suitable form or shape. For example, inner protrusion 8 canbe an uneven, ragged bead or ridge. Inner protrusion 8 can be formedduring or after the coupling of the enlarged ends 4, 5. In an embodimentof the present invention, the inner and outer protrusions are formedsubstantially as described in the '051 patent and the '365 publication.

FIG. 2 shows straight run portions of conduits 2, 3 having an innerdiameter D1, the enlarged ends 4, 5 having an inner diameter D2, and theinner protrusion 8 having an inner diameter D3. In embodiments of thepresent invention, inner diameters D2 of the enlarged ends 4, 5 aresized based on the inner protrusion 8 (e.g., based on the inner diameterD3 of the inner protrusion 8) formed at the joint 6 and/or based on theinner diameter D1 of the straight run portions. Because of the enlargedends 4, 5 at the joint 6, the inner protrusion 8 is positioned “outside”the inner diameter D1 of the straight run or non-belled portion of theconduits 2, 3. Put another way, the inner protrusion 8 is formed outsidethe length-wise path of the non-belled portions of the conduit 1. Thismay allow for a clear, unobstructed passage for the conductor 10 to betraversed or “run” through the continuous conduit 1 such that theconductor 10 does not contact the inner protrusion 8, and therebyavoiding being cut, pierced, or otherwise damaged. Moreover, conductor10 can be traversed through continuous conduit 1 by any suitable means,such as by pulled, pushed, or otherwise “running” the conductor 10through the continuous conduit 1. Additionally, FIG. 2 shows conductor10 spanning a “valley” formed by the enlarged ends 4, 5 such that itdoes not contact the inner protrusion 8.

FIG. 3 is a cross sectional view the continuous conduit 1 along line BBof FIG. 1. As can be seen in FIG. 3, straight run portions (non-belledconduit portions) have an inner diameter D1, the enlarged ends 4, 5 havean inner diameter D2, and the inner protrusion 8 has an inner diameterof D3. The first enlarged end 4 and second enlarged end 5 each have aninner diameter D2 greater than that of the straight-run portions 2, 3.Moreover, inner protrusion 8 has an inner diameter D3 greater than innerdiameter D1 and less than inner diameter D2. For example, first andsecond conduits 2, 3 can have straight run portions with an innerdiameter D1 of 4 inches, the enlarged ends can have a diameter D2 of 4½inches, and internal protrusion 8 can have an internal diameter D3 of 4¼inches. In an aspect of the invention, the diameter D2 should be largeenough such that internal protrusion 8 does not project inward to aposition equal to or less than the diameter D1 of the non-belled portionof the conduits. For example, the maximum permitted inner diameter D3should be at least greater than diameter D1.

Continuous conduit 1 (including first and second conduits 2, 3) can becomprised of any suitable composition or material, including anysuitable formulation of composition or material. For example, in oneembodiment, continuous conduit 1 is comprised of polyethylene. Inanother embodiment, continuous conduit 1 is comprised ofpolyvinylchloride (PVC). In yet another embodiment, continuous conduit 1is comprised of metal. The continuous conduit 1 also can be acombination of compositions or materials.

Though FIG. 1 and FIG. 2 show only first conduit 2 and second conduit 3,embodiments of the present invention are not limited to the coupling ofonly two conduits, and any suitable number of conduits can be coupledtogether in series. For example, FIG. 4 shows three coupling junctionsor joints 6 and corresponding conduit pairs 2, 3. Each joint 6 can beformed with an internal protrusion 8 and an external protrusion 7. Ascan be seen from the lower cross sectional view in FIG. 4, the innerprotrusion 8 of each of the joints does not extend radially inwardly tothe inner diameter of the non-belled portion of the conduits. Thus,conductor 10 can be run through (e.g., pushed or pulled) the series ofconduits without contacting any of the inner protrusions 8. Furthermore,conductor 10 can be housed or maintained within the conduits such thatthe conductor 10 rests on the straight run portions spanning the joint 6without touching or contacting the inner protrusions 8.

FIG. 5 is a flow chart representation of a method 500 for forming acontinuous conduit from two or more individual conduits according to anembodiment of the present invention.

In FIG. 5, while the method 500 can start at 502 and proceed to anysuitable step or operation, FIG. 5 shows the method proceeding from 502to 504, which includes forming an enlarged portion at one or more endsof a conduit. If both ends of the conduit are to be enlarged, the endscan be enlarged substantially simultaneous or one at a time. If one at atime, one end can be enlarged, and then the conduit can be moved suchthat the other end can be enlarged. Alternatively, a means that performsthe enlarging, such as a “beller,” can be moved so as to enlarge theother end. Other conduit ends can also be enlarged simultaneously or insuccession. Although the method 500 shows start 502 immediately followedby 504, 506 can immediately follow start 502, if the ends of the conduitare already bell-shaped or similarly enlarged.

The enlarged portion or portions can be of any suitable configurationand of any suitable dimensions. For example, the enlarged portion orportions can be bell-shaped or otherwise flared, wherein an innerdiameter (i.e., D2) of an end or a “bottom” of the bell is larger thanan inner diameter (i.e., D1) of the non-enlarged portion immediatelyadjacent a “top” of the bell.

After 504 the method can proceed to any suitable operation or step. FIG.5 shows the method proceeding to 506. At 506, an enlarged end of a firstconduit can be positioned adjacent an enlarged end of a second conduitsuch that respective circumferences of the enlarged ends (which are ofsubstantially the same circumference) are substantially axially aligned.For example, the enlarged ends can be positioned for coupling by way offusing substantially as described in the '051 patent. After 506, themethod can proceed to any suitable step or operation. FIG. 5 shows themethod proceeding to 508.

At 508, the positioned and aligned enlarged ends can be coupledtogether. The enlarged ends can be coupled together in any suitable wayand by any suitable means. In an embodiment of the invention, thepositioned and aligned ends are substantially permanently coupledtogether. Moreover, the enlarged ends can be coupled together by anysuitable means, such as welding, fusing, gluing, etc. For example, in anembodiment of the invention, the enlarged ends are fused together usingthe method substantially as described in the '051 patent and the '365publication. The coupling together forms a joint, such as a fuse jointor fused portion. Moreover, the joint can be substantially permanent andseamless.

In coupling the enlarged ends together to form a joint, external andinternal protrusions, such as beads or ridges may be formed at thejoint. The protrusions can take any suitable form and can protrude byany suitable amount. In preferred embodiments, however, the internalprotrusion does not protrude or extend inwardly to a position equal toan inner diameter (i.e., D1) of the non-belled or straight-run portionof the coupled-together conduits. That is to say, the enlarged portionsare sized (e.g., an inner diameter (i.e., D2) is sized) to accommodatethe internal protrusion. Thus, a conductor passed through the continuousconduit may be prevented from contacting the internal protrusion. After508, the method can proceed to any suitable step or operation. FIG. 5shows the method proceeding to 510. Note, however, that 508 may beperformed for any suitable number of first and second conduits to form acontinuous conduit comprised of a plurality of first and second conduitpairs.

At 510, the method includes forming the external protrusion. Theexternal protrusion can be formed into any suitable configuration orshape, by any suitable means, such as a grinder, milling apparatus,planer, cutting apparatus, etc. For example, the external protrusion canbe reduced or substantially removed. Reducing or removing the externalprotrusion may allow for the continuous conduit to be traversed (e.g.,pushed or pulled) through a cavity, such as a man-made cavity, includinga hole, a trench, a ditch, etc., more efficiently. Additionally, theexternal protrusion can be formed to facilitate traversal through acavity. For example, the external protrusion can be formed so as toprevent dirt from accumulating on a leading side thereof as thecontinuous conduit is traversed through the cavity.

After the continuous conduit has been positioned in a cavity, one ormore conductors can be run through the interior of the joined conduitswithout obstruction and without contacting inner beads or ridges thatcould damage the conductors.

The invention having been described in certain embodiments, it will beapparent to those skilled in the art that many changes and alterationscan be made without departing from the spirit or essentialcharacteristics of the invention. Accordingly, Applicant intends toembrace all such alternatives, modifications, equivalents and variationsthat are within the spirit and scope of this invention.

1-15. (canceled)
 16. A non-metallic raceway configured to facilitatepassage of a conductor comprising: at least one pair of non-metallichollow conduits, including a first non-metallic conduit and a secondnon-metallic conduit, the first and second non-metallic hollow conduitseach having: a first belled end portion having belled inner and outersurfaces, the first belled end portion having a first inner diameter atan end thereof, a second belled end portion having belled inner andouter surfaces, the second belled end portion having the first innerdiameter at an end thereof, and a cylindrical portion extending from thefirst belled end portion to the second belled end portion and with asecond uniform inner diameter, the first inner diameter being greaterthan the second uniform inner diameter, the pair of non-metallic hollowconduits being fused together at respective ends of the first belled endportions to form a fused portion, the fused portion including aninternal ridge and an external ridge, and the internal ridge having athird inner diameter, the pair of fused together conduits havinguncovered outer surface portions of the cylindrical portions and anentire outer surface of the fused portion that is uncovered, the thirdinner diameter being greater than the second uniform inner diameter andless than the first inner diameter, and the first, second, and thirdinner diameters being sized such that a conductor passed through theraceway does not contact the internal ridge.
 17. The non-metallicraceway of claim 16, further comprising a plurality of said pairs ofnon-metallic hollow conduits.
 18. The non-metallic raceway of claim 16,wherein the first and the second non-metallic hollow conduits comprisepolyethylene.
 19. The non-metallic raceway of claim 16, wherein thefirst and the second non-metallic hollow conduits comprisepolyvinylchloride (“PVC”).
 20. The non-metallic raceway of claim 16,wherein the internal ridge extends inwardly more than the external ridgeextends outwardly.
 21. A method of forming a continuous conduit from afirst hollow conduit and a second hollow conduit, each of said first andsecond hollow conduits having first and second bell-shaped end portionsand a cylindrical middle portion of uniform inner diameter running fromthe first bell-shaped end portion to the second bell-shaped end portion,the method comprising: positioning the first bell-shaped end portion ofthe first hollow conduit adjacent the first bell-shaped end portion ofthe second hollow conduit such that respective circumferences of ends ofthe hollow conduits are substantially axially aligned, each of saidbell-shaped end portions having belled inner and outer surfaces; andsubstantially permanently fusing the positioned and aligned bell-shapedend portions together to form a fuse joint at the ends of thebell-shaped end portions, said substantially permanently fusing formingan internal protrusion at the fuse joint, the internal protrusionprotruding substantially radially inward, the internal protrusionextending inwardly to an inner diameter greater than that of non-belledportions of the first hollow conduit and the second hollow conduit, andthe substantially permanently fused first and second hollow conduitsforming the continuous conduit have exposed outer surface portions ofthe non-belled portions and an entire outer surface of the fuse jointthat is exposed and are configured so as to prevent a conductor passedthrough the continuous conduit from contacting the internal protrusion.22. The method of claim 21, wherein said substantially permanentlyfusing forms an external protrusion at the fuse joint, the externalprotrusion protruding substantially radially outward, and the methodfurther comprising forming the external protrusion after saidsubstantially permanently fusing.
 23. The method of claim 22, whereinsaid forming the external protrusion includes reducing the externalprotrusion.
 24. The method of claim 22, wherein said forming theexternal protrusion includes substantially removing the externalprotrusion.
 25. The method of claim 21, further comprising: forming thebell-shaped end portion of the first hollow conduit; forming a secondbell-shaped end portion of the first hollow conduit; forming thebell-shaped end portion of the second hollow conduit; and forming asecond bell-shaped end portion of the second hollow conduit.
 26. Themethod of claim 21, further comprising: traversing the continuousconduit through a man-made cavity; and traversing a conductor along aninside of the continuous conduit such that the conductor does notcontact the internal protrusion.
 27. A continuous conduit for housing anelectrical or optical conductor, the conduit comprising: a firstelongated conduit and a second elongated conduit with each elongatedconduit having a cylindrical portion and enlarged ends with a diameterlarger than the cylindrical portion, the cylindrical portion extendingfrom a first enlarged end of the enlarged ends to a second enlarged endthereof and having a uniform inner diameter; and the first enlarged endof the first elongated conduit being coupled to the first enlarged endof the enlarged ends of the second elongated conduit, the coupled firstenlarged ends forming a joint, the joint including a protrusion thatprojects radially inward, and wherein the coupled first and secondelongated conduits having the joint with the inwardly projectingprojection each have entire outer surfaces thereof that are exposed andare configured and operative to house the electrical or opticalconductor so the conductor does not contact the internal ridge.
 28. Thecontinuous conduit of claim 27, wherein the enlarged ends of the firstand second elongated conduits are coupled together by fusion.
 29. Thecontinuous conduit of claim 27, wherein the joint includes a protrusionthat projects radially outward.
 30. The continuous conduit of claim 27,wherein the coupled first and second elongated conduits having the jointwith the inwardly projecting projection are configured to allow theconductor to be passed through the continuous conduit without touchingthe inwardly projecting projection.